We believe our operations have a modest environmental impact. Savings from more efficient usage and recovery of waste and resources can have both a positive benefit for environment and the Company. Our facilities are certified in accordance with ISO 14001 (86%) or in compliance with the principles of ISO 14001 through our internal standard (7%). Our total energy consumption corresponds to 290,000 metric tons CO2 (using the Greenhouse Gas Protocol), an increase of 8% from 2014 due to new facilities and increased production in some facilities.
Our facilities reduce waste and scrap through annual policy deployment targets. In steering wheels manufacturing, conventional polyurethane foaming can result in foam leaking through the mold’s venting holes causing up to 20% of material waste. Our global process team reduced waste by 30% in this process through tooling improvement and reduced waste by 70% in our China Steering Wheel operation through a new vacuum process.
Our facilities are succeeding in improving energy efficiency and reducing water usage through continuous process improvement. Autoliv is making strides in energy reduction using various methods, including upgrading lighting to LED, automatic light power controls, and air conditioning temperature and time controls. One significant achievement in energy reduction is a direct result of continuous improvement and our Lean Manufacturing principles. In our Utah airbag module facility, we reduced energy used per airbag module produced by 50%, from 1 kWh in 2010 to less than 0.5 kWh per part produced.
Air compressors in some manufacturing processes use oil to cool engine temperature, resulting in waste heat loss. In Turkey we designed an application to recover this waste heat. A proportion of this waste heat will be transferred to the heating and hot water production system, reducing natural gas consumption. In the winter, 100% of compressor waste heat will be recovered and during the summer 35%.
Conventional steering wheel manufacturing processes use solvent chemicals for leather wrapping gluing and polyurethane foaming. In anticipation of future regulations, to reduce the environmental impact of these chemicals, and to improve working conditions for our employees, Autoliv made a global decision to move from chemical-based to water-based solvent and processes decreasing the solvent chemical glue in our products from 50% to 18% globally to date.
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